Instruction Manual

for Freshwater Generator

Type JWP-26-C80/100

Serial No.: ____________________

Shipname/
Hull No.: ____________________

Customer: ____________________

Book Number O26WE08.fm

Alfa Laval reserve the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement
of this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

Published by: Alfa Laval Desalt A/S

Maskinvej 5
DK-2860 Søborg
(Copenhagen) Denmark

© Copyright Alfa Laval Desalt.

This document and its content must not be copied, reproduced, transmitted or dis-
closed to any third party without consent of Alfa Laval Desalt.

2 O26WE08.fm
 Table of Contents

Safety Instructions and Warnings

1.0.0 Safety Instructions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5

System Description
1.0.0 Working Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
1.1.0 Freshwater Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7
1.2.0 Main Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8

Operating Instructions
1.0.0 Starting and Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
1.1.0 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
1.1.1 Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
1.1.2 Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
1.2.0 Adjustment of Hot Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
1.3.0 Adjustment of Sea Cooling Water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.4.0 Stopping the Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
1.5.0 Long Term Standstill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12

Maintenance
1.0.0 Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . page 13
1.1.0 Overhaul Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
1.2.0 Maintenance of Separator Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14
1.3.0 Maintenance of Evaporator Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
1.4.0 Maintenance of Condenser Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
1.5.0 Renewal of Plate Heat Exchanger Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . page 18
1.5.1 Removal of Old Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
1.5.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
1.5.3 Preparation of New Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
1.5.4 Fitting New Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19

Chemical Dosing of Scale Control Chemicals

1.0.0 Prevention of Scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
1.1.0 Feed Water Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
1.2.0 Chemical Dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
1.2.1 Scale Inhibitor Dosage Equipment for Feed Water . . . . . . . . . . . . . . . . . . . page 22
1.2.2 Safety Precautions with the use of Chemicals . . . . . . . . . . . . . . . . . . . . . . . page 23

Trouble-Shooting
1.0.0 Test Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25

O26WE08TOC.fm 3
Table of Contents

1.1.0 Trouble Shooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25

Maintenance of Freshwater Pump

1.0.0 Maintenance of Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . page 29
1.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
1.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30
1.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 30

Maintenance of Ejector Pump

1.0.0 Maintenance of Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33
1.1.0 Overhaul of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33
1.1.1 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
1.1.2 Dismantling Pump Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36

Salinometer
1.0.0 Salinometer Type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
1.1.0 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
1.2.0 Installation (for DS-20). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
1.3.0 Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
1.3.1 Testing the Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
1.3.2 Adjustment of Alarm Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
1.3.3 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39

Spare Parts
1.0.0 Ordering Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41
1.1.0 Alfa Laval Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41

Index

4 O26WE08TOC.fm
 Safety Instructions and Warnings

Should you need further clarification regarding this manual, do not hesitate to con-
tact your local Alfa Laval representative - or call Alfa Laval Desalt directly.

Telephone +45 (for Denmark) 39 53 60 00

Telefax +45 (for Denmark) 39 53 65 66

1.0.0 Safety Instructions and Warnings

The following symbols in this manual point out safety precautions. It means your at-
tention is needed and your safety is involved.

WARNING

This symbol is used to indicate the presence of a hazard which can or will
cause severe personal injury, if the warning is ignored.

CAUTION

Certain passages of the text will be marked with a caution mark. This mark
indicates the presence of hazard which will or can cause property damage
if the instructions are not observed.

NOTE

This type of instruction indicates a situation which, if not avoided, could re-
sult in damage to the equipment.

It is the owner’s and operator’s responsibility to see that any person involved
with the use or operation of this equipment follow all safety instructions.

Read all safety instructions carefully and insist that they will be followed by
those working with you and for you. Not following the instructions may cause
severe personal injury or damage the equipment beyond repair.

Do not allow this equipment to be used if it is faulty or the operator does not
understand the proper use.

Samare04.fm 5
Safety Instructions and Warnings

WARNING

The freshwater generator is not to be operated in polluted water or within

20 miles from the coast

Freshwater must not be produced from polluted water, as the produced water can
be unsuitable for human consumption.

If manuals are translated to local language the unit comply with the EEC Machinery
Directive and EN 292-1/2 standards. For EEC land installations manuals MUST be
available in local language before installing and operating the unit.

The unit also comply with EN 50081-2 and EN 50082-2 “Industry” with regards to the
EMC directive from EEC.

WARNING

Noise hazards
• Use ear protection in noisy environments.

Crush hazards
• Use correct lifting tools.
• Do not work under hanging load.

Burn hazard
• Wear gloves to avoid burns by hot surfaces.

Cut hazards
• Wear gloves to avoid cuts by sharp edges when handling machined
parts.
• Wear helmet to avoid cuts by sharp edges during maintenance of the
equipment.

NOTE

• Max. ambient temperature for the equipment is 50°C (122°F).

• Min. ambient temperature for the equipment is 0°C (32°F).

6 Samare04.fm
 System Description

1.0.0 Working Principle

The combined brine/air ejector driven by the ejector pump creates a vacuum in the
system in order to lower the evaporation temperature of the feedwater.

The feedwater is introduced into the evaporator section through an spring loaded
valve (full open by 2 bar) orifice, and is distributed into every second plate channel
(evaporation channels).

The hot water is distributed into the remaining channels, thus transferring its heat to
the feedwater in the evaporation channels.

Having reached boiling temperature - which is lower than at atmospheric pressure -

the feed water undergoes a partial evaporation, and the mixture of generated vapour
and brine enters the separator vessel, where the brine is separated from the vapour
and extracted by the combined brine/air ejector.

Having passed a demister the vapour enters every second plate channel in the top
of the condenser section.

The sea cooling water supplied to the condenser by the combined cooling/ejector
water pump distributes itself into the remaining condenser channels, thus absorbing
the heat being transferred from the condensing vapour.

From outlet side the condenser, the sea cooling water is used as jet water for the
ejector and as feed water for evaporation.

The produced freshwater is extracted by the freshwater pump and led to the fresh-
water tank.

1.1.0 Freshwater Quality

To continuously check the actual salinity of the produced freshwater, a salinometer
is provided together with an electrode unit fitted on the freshwater pump delivery
side.

If the salinity of the produced freshwater exceeds the chosen maximum value, the
dump valve and alarm are activated to automatically dump the produced freshwater
to the bilge.

If there are no special requirements from the authorities, the produced freshwater
can be used directly as drinking water.

Sy1jwe00.fm 7
System Description

1.2.0 Main Components

The freshwater generator consists of the following components:

1. Evaporator section
The evaporator section consists of a plate heat exchanger and is enclosed in
the separator vessel.

2. Separator vessel
The separator separates the brine from the vapour.

3. Condenser section
Just like the evaporator section the condenser section consists of a plate heat
exchanger enclosed in the separator vessel.

4. Combined brine/air ejector

The ejector extracts brine and incondensable gases from the separator vessel.

5. Ejector pump
Normally, the ejector pump is delivered by Alfa Laval, and the ejector pump is
a single-stage centrifugal pump. This pump supplies the condenser with sea
cooling water and the brine/air ejector with jet water as well as feed water for
evaporation.

6. Freshwater pump
The freshwater pump is a single-stage centrifugal pump. The freshwater pump
extracts the produced freshwater from the condenser, and pumps the water to
the freshwater tank.

7. Salinometer
The salinometer continuously checks the salinity of the produced water. The
alarm set point is adjustable.

8. Control panel
Normally, the control panel is delivered by Alfa Laval. It contains motor starters,
running lights, salinometer, contacts for remote alarm and is prepared for start/
stop.

8 Sy1jwe00.fm
 Operating Instructions

WARNING

DO NOT operate the plant in polluted water.

Freshwater must not be produced from polluted water, as the produced water will be
unsuitable for human consumption.

1.0.0 Starting and Stopping Procedure

CAUTION

Before starting up please observe instructions for feedwater treatment, see

“Chemical dosing of scale control chemicals”.

Please refer to PI-diagram (see “FWG Order Specification”).

1.1.0 Starting
1. Open valves on the suction and discharge side of the ejector pump
PU-SC-01.

2. Open overboard valve for combined brine/air ejector.

3. Close air screw VA-E1-01 on the separator.

4. Start ejector pump PU-SC-01 to create a vacuum of min. 90%.

Pressure at combined brine/air ejector inlet minimum 300 kPa (3.0 kp/cm²).
Back pressure at combined brine/air ejector outlet maximum 60 kPa (0.6 kp/
cm²).

1.1.1 Evaporation
When there is a minimum of 90% vacuum (after maximum 10 minutes).

5. Open valve for feedwater treatment, if any.

Opjwe00.fm 9
Operating Instructions

6. Open hot water inlet and outlet valves.

7. Start hot water supply to distiller by adjusting bypass valve or hot water pump
if any, step-wise 10°C, until the desired jacket water temperature is reached.

The boiling temperature now rises, while the obtained vacuum drops to approx.
85%.

This indicates that evaporation has started.

1.1.2 Condensation
After approx. 3 minutes the boiling temperature will drop again, and normal vacuum
is reestablished.

8. Open valve to freshwater tank.

9. Switch on salinometer.

10. Start freshwater pump PU-FR-01/PU-FR-02.

NOTE

The freshwater pump discharge pressure will be between 120 and 160 kPa
(1.2 - 1.6 kp/cm²).

After starting the freshwater pump the flow sight glass in the air suction pipe must
be empty.

CAUTION

If water remains in the flow sight glass in the air suction pipe, please refer
to “Trouble shooting”.

1.2.0 Adjustment of Hot Water Flow

Please refer to “FWG Order Specification” for specified hot water flow.

In order to obtain the specified flow of hot water, it is necessary to adjust the bypass
valve until desired flow is achieved.

10 Opjwe00.fm
 Operating Instructions

The flow can be calculated as follows:

MJW = KJW × cap.m³/24h =m³/h

∆tJW

Where:

MJW = Flow of hot water in one hour.

KJW = Constant =25.6 for 1-stage freshwater generator.

KJW = Constant =15.52 for 2-stage freshwater generator.

∆tJW = Difference in temperature of hot water in and out.

Cap.m³/24h = Freshwater production in 24 hours, i.e. production in 5

min. times 288.

Example: cap. m³/24h = 15 m³

TSW = 32°C
∆tJW =18.4°C

MJW = 25.6 × 15 ................= 20.9 m³/h

18.4

1.3.0 Adjustment of Sea Cooling Water

The sea cooling water flow is correct, when the pressure at the inlet side of the com-
bined air/brine ejector is between 300 and 400 kPa (3.0 - 4.0 kp/cm²).

1.4.0 Stopping the Plant

1. Stop hot water supply to distiller.

2. Close valve for feedwater treatment, if any.

3. Stop freshwater pump PU-FR-01/PU-FR-02.

4. Switch off salinometer.

5. Stop ejector pump PU-SC-01.

6. Open air screw VA-E1-01.

Opjwe00.fm 11
Operating Instructions

7. Close valves on the suction and discharge side of the ejector pump.

8. Close overboard valve for combined brine/air ejector.

9. Close the valve to freshwater tank.

CAUTION

All valves must be shut, while the distiller is out of operation. Except air
screw.

1.5.0 Long Term Standstill

If the distiller is out of operation for a period longer than 14 days.

• Open front covers and clean unit inside with freshwater.

• Let the unit dry out completely, before closing covers.

Please observe “Maintenance of separator vessel”.

12 Opjwe00.fm
 Maintenance

1.0.0 Why you need to perform regular maintenance duties

Regular maintenance of the plant will improve performance and availability.

The maintenance schedule on the following pages will tell you how often service
should be performed on the main components.

As the actual operating conditions of the plant are of major influence on the life time,
the overhaul dates are not obligatory but only recommended intervals.

When the plant has been in operation for a longer period of time and experience has
been established as to the actual performance, it will be possible to adapt the main-
tenance schedule.

For service on minor components please refer to component instructions.

1.1.0 Overhaul Intervals

Component Operating Hours Action

Evaporator section As required Clean in inhibited acid bath
Condenser action As required Clean with pure freshwater and
brush
Separator vessel with an- 2000 h See separator instructions
odes

Combined ejector/cool- 8000 h Measure seal ring and impeller.

ing water pump with mo- Examine mechanical shaft
tor seal, cooling water pipe pas-
sage.
Megger-test electric motor.
Clean pump thoroughly before
reassembly.

Freshwater extraction 8000 h See above

pump with motor
Combined air/brine ejec- 8000 h Measure nozzles and diffuser
tor and compare to measurements
in technical specification.
Max. wear 20% on diffuser cy-
lindrical bore.

Majwpe00.fm 13
Maintenance

Component Operating Hours Action

MV-valves 4000 h Disassembly and inspect for
damage
Demister 8000 h Clean in inhibited acid bath

Manometers 8000 h Adjust with control manometer

Salinometer See “Maintenance See “Maintenance of salinome-

of salinometer type ter type DS-20”
DS-20”

1.2.0 Maintenance of Separator Vessel

The front cover and the pressure plates for the heat exchanger sections (evaporator
and condenser) are made of stainless steel with a special chemical treatment. This
treatment will reestablish normal surface oxidation after work- up at the factory. The
preparation is a natural protection of the stainless steel.

CAUTION

To preserve this natural protection DO NOT scrape or scratch the inside

surface of the front cover.

Whenever the separator vessel is opened,

• check that the anodes are functioning.

If the anodes are not functioning and/or scarified, replace them.

NOTE

If the unit is stopped for a longer period than 14 days.

• Open front covers and clean unit inside with freshwater.

• Let the unit dry out completely, before closing covers.

14 Majwpe00.fm
 Maintenance

1.3.0 Maintenance of Evaporator Section

Clean evaporator as follows:

1. Remove bolts in front cover, and open.

2. Loosen the

2 nuts for P-16 distiller

4 nuts for P-26 distiller

in plate stack gradually, so that no nut is carrying the entire load alone.

3. Remove plate stack.

NOTE

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Submerge plates completely in a hot, inhibited acid bath at maximum 50ºC. For
further instructions see “Chemical dosing of scale control chemicals”.

WARNING

Always follow carefully the suppliers instructions when using inhibited ac-
ids.

Remember to neutralize according to suppliers instructions.

5. Examine plates and gaskets for possible damage, and remove damaged plates
and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate together with one of the adjacent
plates.

Majwpe00.fm 15
Maintenance

NOTE

The assembly measurements must be reduced with

2.8 mm for P-16 distiller

3.5 mm for P-26 distiller

per plate, if plates are removed from plate stack.

CAUTION

The ES and EE plate cannot be removed but must always be replaced with
a corresponding plate.

7. Reassemble evaporator section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test evaporator section before closing front cover.

The evaporator section is pressure tested by letting hot water circulate through
the section with bypass valve for hot water in normal running position.

10. When the evaporator section is found to be tight, close front cover and tighten
bolts.

11. Retighten cover, when vacuum has been reestablished.

1.4.0 Maintenance of Condenser Section

Clean condenser as follows:

1. Remove bolts in front cover, and open.

2. Loosen the

2 nuts for P-16 distiller

6 nuts for P-26 distiller

in plate stack gradually, so that no nut is carrying the entire load alone.

3. Remove plate stack.

16 Majwpe00.fm
 Maintenance

NOTE

If some of the gaskets come loose on removing plate stack, please see
section 1.5.2

4. Scrub plates with a soft brush and plain hot water at maximum 50ºC.

5. Examine plates and gaskets for possible damage, and remove damaged plates
and/or replace damaged gaskets.

6. If a defective plate is found, remove the plate and one of the adjacent plates.

NOTE

The assembly measurements must be reduced with

2.8 mm for P-16 distiller

3.5 mm for P-26 distiller

per plate, if plates are removed from plate stack.

CAUTION

The KS and KE plate cannot be removed but must always be replaced with
a corresponding plate.

7. Reassemble condenser section in accordance with assembly scheme.

8. Tighten plate stack to measurements stated in technical specification.

9. Pressure test condenser section before closing front cover.

The condenser section is pressure tested by letting sea water from the com-
bined cooling water/ejector pump circulate through the section.

Majwpe00.fm 17
Maintenance

CAUTION

Before starting the combined ejector/cooling water pump, the feed water
must be sealed off.

10. When the condenser section is found to be tight, close front cover and tighten
bolts.

11. Retighten, when vacuum has been reestablished.

12. Do not forget to remove the feed water sealing as mentioned above.

1.5.0 Renewal of Plate Heat Exchanger Gaskets

1.5.1 Removal of Old Gaskets

Pull the old gaskets out of groove.

If the gasket cannot come off directly, heat the back of the gasket groove with a
hot-air blower or butane gas burner.

Pay attention not to overheat the plates.

You will obtain a suitable temperature, if the flame is held 10 to 15 cm behind the
plate.

WARNING

DO NOT use acetylene gas.

1.5.2 Cleaning
Charred or loose glue and rubber remains must be removed, e.g. using a rotating
stainless steel brush. The width should be adapted (Ø40-50 mm, width 8-10 mm).
Thin layers of glue which are difficult to remove, may remain.

Clean the gasket groove with a clean cloth, dipped in a solvent (acetone, methyl eth-
yl ketone, trichlorethylene etc.).

18 Majwpe00.fm
 Maintenance

WARNING

Be careful when handling these solvents, as they may be hazardous to

your health.

Observe suppliers’ instructions.

Gaskets, that have loosened, can be glued on. Clean gasket groove carefully with a
sharp tool. Then clean the loose part of the gasket with emery cloth or sandpaper.
Finally clean groove and gasket with a solvent, and glue.

1.5.3 Preparation of New Gaskets

Dry new gaskets with a clean cloth that has been slightly moistened with a solvent.

1.5.4 Fitting New Gaskets

1. Apply a thin layer of glue to both gasket and groove.

2. Let the glue dry for 10-15 minutes.

3. Fit new gasket into groove.

Gaskets may sometimes be slightly short or long.

Short gaskets should be stretched before being fitted into the groove.

Long gaskets should be fitted into the grooves at the plate ends first and then grad-
ually be pushed into the groove towards the middle.

If necessary, tape gasket into groove.

Majwpe00.fm 19
Maintenance

20 Majwpe00.fm
 Chemical Dosing of Scale Control Chemicals

1.0.0 Prevention of Scaling

During the evaporation of sea water there is always a risk of scaling on the heating
surfaces. This will lead to a reduction of the K-values of the heating surface and de-
creasing freshwater production and reduction of plant efficiency.

In order to effectively prevent scaling the operators must be aware of the factors in-
fluencing the scale formation.

1.1.0 Feed Water Ratio

The feedwater ratio is an extremely important factor. It is defined by the relationship
between the feedwater amount fed into the plant and the produced amount of fresh-
water.

If the feedwater ratio is reduced, the concentration will rise in the plant subsequently
resulting in scale formations.

Two things may shift the feedwater ratio: first of all direct adjustment of the feedwater
system, and secondly exceeding the maximum freshwater production laid out for the
plant. The operators must observe the following rules at all times.

CAUTION

DO NOT adjust feedwater system. Feedwater pressure min. 3.0 max. 4.0
bar g.

1.2.0 Chemical Dosage

In order to control scale formations on the heating surfaces and continuously ensure
long operation periods without acid cleaning the plant, it is absolutely necessary to
dose scale control additives to the feedwater. The operators must follow the instruc-
tions for chemical dosing given by the chemical supplier carefully.

Cdgnpe00.fm 21
Chemical Dosing of Scale Control Chemicals

CAUTION

If the distiller is operated at boiling temperatures above 45°C without chem-

icals, frequent cleaning of the evaporator will be necessary.

We recommend that you do not operate the freshwater distiller without rec-
ommended chemical dosage at boiling temperatures above 45°C. Even at
lower temperatures it can be recommended.

1.2.1 Scale Inhibitor Dosage Equipment for Feed Water

Please refer to drawing, see “FWG Order Specification”.

• When adding chemicals mix thoroughly to ensure a homogenous blend of

chemicals and water.

Use a fully soluble scale inhibitor, e.g. on polymer basis. The following products can
be recommended:

NALFLEET Evaporator treatment 9-913

AMEROYAL EVAPORATOR TREATMENT

HEXAMETHAPHOSPHATE

1. Mix the required quantity for 24 hours operation in the tank according to mak-
er’s instructions.

2. Adjust flowmeter to cover the maximum freshwater output from the distiller.

3. Flush the dosage system regularly.

22 Cdgnpe00.fm
 Chemical Dosing of Scale Control Chemicals

1.2.2 Safety Precautions with the use of Chemicals

WARNING

1 USE eye protection and gloves. Avoid direct skin contact, eye contact
or contact with clothes.

2 CLEAN empty containers before disposal.

3 If chemicals are spilled on clothes, rinse with water and dispose off
clothes.

4 If chemicals are spilled on the floor, rinse with water and suck remain-
ing chemicals off with sand. Clean the spot immediately afterwards.

5 Scale inhibitor is hazardous, if consumed in a concentrated solution.

If consumed by mistake.
IMMEDIATELY SEEK MEDICAL ATTENTION.

6 If eyes get in contact with the chemicals, rinse for at least 20 minutes.
IMMEDIATELY SEEK MEDICAL ATTENTION.

Cdgnpe00.fm 23
Chemical Dosing of Scale Control Chemicals

24 Cdgnpe00.fm
 Trouble-Shooting

1.0.0 Test Sheet

Before taking any action, please fill in a test sheet to find possible causes of malfunc-
tions.

Test sheets can be found in the back of this binder.

1.1.0 Trouble Shooting Table

Problem Cause Action

Drop in production. Partially blocked feed water Dismantle evaporator section,

orifice and/or sludge deposits and clean evaporator and ori-
on hot water side. fice.

Sludge on the heat exchanger Dismantle condenser section,

plates on the sea water side. and clean.

Inlet channel in evaporator/ Dismantle evaporator/ con-

condenser plate stack denser section, and clean.
blocked, e.g. with rust scales,
gasket fragments etc.

Too low ejector pump pres- See instructions for “Low Sea
sure. Cooling water/Ejector pump
flow / pressure”, below.

Leakages Carry out a pressure test at

max. 150 kPa (1.5 kp/cm²)
(21.8 PSI).a

Foreign bodies in ejector noz- Inspect nozzles, and clean.

zles. Replace nozzles, if damaged.

Too high back pressure on Check overboard pipe and

ejector outlet side. Max 60 valves for blocking / function-
kPa (0.6 kp/cm²) (8.7 PSI). ability.

Non-return valve in air extrac- Replace non-return valve.

tion pipe defect.

Hot water temperature too Reduce to specified tempera-

high. ture.

Defective water clock. Examine water clock. Let the

produced water flow through
water clock into a 10 l pail, and
check production with a stop
watch.

Trw26e03.fm 25
Trouble-Shooting

Problem Cause Action

Low Sea Cooling water/Ejector Too low ejector pump pres- Clean, or replace pressure
pump flow / pressure. sure. gauge.
Minimum pressure 300 kPa
(3.0 kp/cm²) (43.5 PSI). Suction strainer blocked. Clean suction strainer.
At inlet side of ejector.
Valves on suction or pressure Examine and overhaul defec-
pipe defect. tive valves.

Leakage from suction pipe to Repair.

pump.

Impeller / seal ring defective. Check pump maximum clear-

ance See “Maintenance of
Ejector Pump”

Clocked up condenser plate Dismantle condenser plate

stack. stack and clean.

Pump rotating in wrong direc- Interchange phases.

tion.

Sight glass overflow. Normal Suction pipe leakage. Check suction pipe especially
back pressure for freshwater unions and connections. Re-
pump is 120 - 160 kPa (1.2 - pair.
1.6 kp/cm²) (17.4 - 23.2 PSI).
Except for JWP-16-C40 gener- Mechanical seal in freshwater Replace mechanical seal.
ator type, where the max. back pump defect.
pressure is 80 kPa (0.8 kp/cm²)
(11.6 PSI). Impeller / seal ring in freshwa- Check pump maximum clear-
ter extraction pipe defect. ance See “Maintenance of
Freshwater Pump”

Pump rotating in wrong direc- Interchange phases.

tion.

Valves to freshwater tank Check all valves.

closed.

Inlet filter for water clock Clean filter.

blocked.

Salinity too high (more than 2.0 Demister not fitted correctly. Check that demister is fitted
ppm). against baffle and front cover.

Front cover gasket defect or Replace front cover gasket.

not fitted correctly.

Insufficient brine extraction. See separate instructions for

insufficient brine extraction,
below.

Electrode unit defective or Examine electrode unit for

dirty. cracks. Check that it is fitted
correctly. Clean, if necessary.

26 Trw26e03.fm
 Trouble-Shooting

Problem Cause Action

Leakage in condenser sec- Open distiller and pressure test

tion. condenser. Max. 600 kPa (6.0
kp/cm²) (87 PSI). If there is a
defective plate, remove togeth-
er with adjacent plate assem-
ble plate stack according to
new plate number with re-
duced assembly measure-
ments. Check plate gaskets
and replace, if necessary.

Insufficient brine extraction - Ejector pump pressure too See special instructions for
brine level in sight glass higher low. “Low Sea Cooling water/Ejec-
than 20 mm. tor pump flow / pressure”,
above.

Foreign bodies in ejector noz- Check nozzles, and clean. Re-

zles. place damaged nozzles.

Too high back pressure down- Examine overboard pipe and

stream of ejector. valves.

Wrong dimension of feedwa- Examine orifice dimension -

ter orifice. check technical specification.

Non-return valve in brine suc- Examine valve and repair, or

tion pipe of ejector defect. replace.

Frequent refill of freshwater Leakage in evaporator sec- Open distiller and pressure test
expansion tank due to loss of tion. condenser. Max. 600 kPa (6.0
hot water. kp/cm²) (87 PSI).
If there is a defective plate, re-
move together with adjacent
plates assemble plate stack
according to new plate number
with reduced assembly mea-
surements. Check plate gas-
kets and replace, if necessary.

Abnormal amperage con- Ejector nozzles defective. Replace nozzles.

sumption of ejector pump mo-
tor. Wrong dimension of feedwa- Check dimensions on spare
ter inlet orifice. parts list, See List of spare part
drawings”, and replace if nec-
essary.

Bearings in motor defective. Examine with stetoscope, and

replace bearings, if defective.

Contactor defective. Examine and replace contactor

set, if defective.

Breaking of phases. Max. 5% difference in amper-

age between phases.

Trw26e03.fm 27
Trouble-Shooting

28 Trw26e03.fm
 Maintenance of Freshwater Pump

1.0.0 Maintenance of Freshwater Pump Types PVVF 1525-1532-2040

The following instructions must be carefully observed whenever it becomes neces-
sary to overhaul or repair the freshwater pump.

Please refer to drawing for item references in the text.

1.1.0 Overhaul of the Pump

1. Remove the nuts 14 on the pump casing 1.

2. Lift motor with pump cover 4 and impeller 2 clear of pump casing 1.

3. Unscrew countersunk screw 20 (right hand thread).

4. Remove impeller. Normally, it can be removed without using dismantling tools.

5. Remove key 19.

6. Remove the mechanical shaft seal 22.

7. Inspect the ceramic ring, the carbon ring and the spring.

8. Replace mechanical shaft seal, if necessary. It is recommended to grease the

shaft and seat for the ceramic ring with glycerine in order to make it easier to
assemble the mechanical shaft seal. Please also observe separate instruc-
tions for mechanical shaft seal delivered together with the seal.

Mapvfe00.fm 29
Maintenance of Freshwater Pump

9. Fit carbon ring, spring and spring holder on pump shaft.

10. Inspect impeller and the drilled sealing water channel for clogging, and clean.
11. Remember to replace gasket 3.

12. Reassemble in reverse order.

1.1.1 Clearance
In connection with the inspection be sure to measure the impeller and wear ring 17
in order to secure that the clearance is no more than 0.5 mm on the diameter.

CAUTION

The pump shaft 11 must only be dismantled, if pump shaft or electric mo-
tor bearing has to be replaced.

In this case carefully observe “Dismantling pump shaft”.

1.1.2 Dismantling Pump Shaft

1. Dismantle the pump as described above.

2. Unscrew pointed screws 11.

3. Carefully insert two screw drivers behind the pump shaft, and loosen it.

If the pump shaft does not come loose, use the special dismantling tools shown
below.

The tool is not Alfa Laval Desalt supply.

30 Mapvfe00.fm
 Maintenance of Freshwater Pump

The tool consists of a pipe (A), a disc (B) with hole for the screw (C) and a nut
(D), washer (E).

Please note that the length L must be longer than the length l.

Place pipe around the shaft. Fasten the screw with nut and washer into the
threaded hole (M12) on the shaft end.

Loosen shaft by tightening the nut while holding on to the screw.

CAUTION

DO NOT grind the motor shaft.

4. Mount the new pump shaft on the motor shaft.

5. Make sure that the pump shaft fits the motor shaft without any obstructions, be-
fore final shaft fitting as follows:

• Tap onto the end of the pump shaft slightly with a RUBBER hammer.

6. Tighten pointed screws 11 as follows:

Mapvfe00.fm 31
Maintenance of Freshwater Pump

NOTE

The torque should be 5 Nm (0.5 kpm) and the maximum wobble 60 µ.m.

7. Check the wobble of the pump shaft with a dial indicator.

8. Assemble the pump as described above.

32 Mapvfe00.fm
 Maintenance of Ejector Pump

1.0.0 Maintenance of Ejector Pump

(If supplied from Alfa Laval)

The following instructions must be carefully observed whenever it becomes neces-

sary to overhaul or repair the above mentioned pump. Please refer to drawing for
item references in the text.

1.1.0 Overhaul of the Pump

1. Remove the set screws 19 in pump cover 2.

Motor with motor bracket 6, pump cover 2, and impeller 5 can now be lifted
clear of the pump casing 1.

2. Unscrew the screw 22 (right-hand thread).

3. Remove impeller.

Macnle00.fm 33
Maintenance of Ejector Pump

NOTE

Normally, the impeller can be removed without using dismantling tools.

If not, you can fit dismantling screws into the two threaded holes in the im-
peller.

4. Remove the key 26 and the mechanical seal 8 (including spring holder, spring
and carbon ring).

5. Inspect the ceramic ring, the carbon ring and the spring. Replace, if necessary

If mechanical seal has to be replaced, proceed as follows:

• Unscrew set screw 20 to remove pump cover 2 from motor bracket 6

in order to gain access to ceramic ring.

In order to make it easier to assemble the mechanical seal, the shaft and ring
seat may be greased with glycerine. Please also refer to separate instructions
for mechanical seal delivered together with the seal.

• After fitting the ceramic ring, fit pump cover 2 to motor bracket 6.

• Fit carbon ring, spring and spring holder.

6. Clean drilled cooling water channel in pump cover 2.

7. Inspect impeller and threaded holes for clogging.

8. Remember to change the O-ring 7.

9. Reassemble in reverse order.

1.1.1 Clearance
In connection with the inspection, the impeller 5 and wear rings 10 are measured
in order to secure that the clearance is not larger than stated in the diagram below.

34 Macnle00.fm
 Maintenance of Ejector Pump

Wear ring Ø Clearance maximum Clearance minimum

100 mm 0.5 mm 0.15 mm
150 mm 0.6 mm 0.2 mm
200 mm 0.7 mm 0.25 mm

250 mm 0.8 mm 0.28 mm

300 mm 0.85 mm 0.3 mm
350 mm 0.9 mm 0.3 mm

If the clearance is too big, replace wear rings as follows:

1. Unscrew countersunk screws 25.

2. Pull out wear (seal) rings.

3. Fit new wear rings and tighten countersunk screws.

CAUTION

The pump shaft may only be dismantled, if pump shaft or bearings, in the
electric motor have to be replaced.

Carefully observe instructions for “Dismantling pump shaft”.

Macnle00.fm 35
Maintenance of Ejector Pump

1.1.2 Dismantling Pump Shaft

If the shaft 4 has to be dismantled due to a defect or if electric motor bearing has to
be replaced, proceed as follows:

1. Unscrew pointed screws 16.

2. Remove shaft 4. Normally this can be done without using dismantling tools.

CAUTION

DO NOT grind the motor shaft.

3. Fit shaft 4.

4. In order to make sure that the coupling is fitted correctly, tap slightly at the shaft
end with a RUBBER hammer.

5. Tighten pointed screws 16 with a torque of 35 Nm (3.5 kpm).

36 Macnle00.fm
 Salinometer

1.0.0 Salinometer Type DS-20

1.1.0 Technical Specification

Function Measuring (Dot Bar) and supervising salinity of

freshwater produced by seawater desalination.

Supply voltage 90-120 V or 200-240 V AC.

Frequency 50/60 Hz
Power consumption Salinometer 10 VA.

Relay contacts Max. load 100 VA.

Salinity display 0,5 - 20 ppm (Dot Bar).
Temperature correction Automatic in the range 5 - 85°C.
Alarm level Can be set to any value between 0,5 - 20 ppm.
Test Can be checked by test switch, 10 ppm.

Output 4-20 mA Current Loop.

Max. ambient tempera- 55°C.
ture
Protection degree IP 54.

1.2.0 Installation (for DS-20)

1. Open front cover.

2. Select correct voltage select according to the main supply voltage 115 V or 230
VAC.

3. Screw salinometer on to bulkhead with six nuts.

4. Connect necessary cables to the terminals.

5. Close front cover.

6. Test salinometer function (see instructions for use).

Salise00.fm 37
Salinometer

1.3.0 Instructions for use

1. Switch on mains.

2. Switch on sec. alarm.

Green pilot LED should light up. Dot. Bar displays the measured salinity.

1.3.1 Testing the Instrument

WARNING

The salinometer must be tested at least once a month, and the electrode
unit must be cleaned.

Push TEST switch on.

The Dot Bar should read 10 ppm.

If the alarm level is less than 10 ppm, the salinometer will give an alarm.

1.3.2 Adjustment of Alarm Level

1. Switch “MAINS” on.

2. Push sec. alarm off.

3. Adjust Alarm Set to desired alarm level by using the switches.

4. Switch “Sec. Alarm” on.

The salinometer is now ready for use.

If the salinity exceeds the alarm level,

• The two red alarm LEDS flash.

• Solenoid valve is activated.

• Buzzer (if fitted) and external alarm system is activated.

Cancel buzzer and external alarm system by switching “Sec. Alarm” off. Solenoid
valve is not affected.

Switch “Sec. Alarm” on as soon as the salinity is normal again; i.e. when the two red

38 Salise00.fm
 Salinometer

LEDS are off.

1.3.3 Maintenance

CAUTION

Remove electrode unit and inspect/clean after every 1000 hours of opera-
tion. Use a clean and dry rag. Avoid touching the electrodes with the fin-
gers.

Salise00.fm 39
Salinometer

40 Salise00.fm
 Spare Parts

1.0.0 Ordering Spare Parts

When ordering spare parts please always state:

1. Serial number.

2. Capacity.

3. Designation.

4. Spare parts drawing number.

5. Position number.

6. Article number.

In order to identify article numbers, please refer to FWG Order Specification and oth-
er drawings.

When ordering parts for pumps proceed as follows:

1. Find article number in the list of drawings.

2. Check spare part drawing and item list with corresponding article number to
identify the item to be ordered.

1.1.0 Alfa Laval Service

The Alfa Laval group is represented in all major ports of the world.

DO NOT hesitate to contact your Alfa Laval representative if you have any ques-
tions, problems or require spare parts.

Spmare01.fm 41
Spare Parts

42 Spmare01.fm
 Index

A
Adjustment of alarm level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Adjustment of hot water flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10
Adjustment of sea cooling water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
Alfa Laval service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41

C
Chemical dosage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 34
Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 10

D
Dismantling pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 36

E
Ejector Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33
Evaporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9

F
Feed water ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21
Fitting new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Freshwater Pump Types PVVF 1525-1532-2040 . . . . . . . . . . . . . . . . . . . . . . . . page 29
Freshwater quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

I
Installation (for DS-20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
Instructions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38

L
Long term standstill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 12

M
Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 39
Maintenance of condenser section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 16
Maintenance of ejector pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33
Maintenance of evaporator section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 15
Maintenance of Freshwater pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 29
Maintenance of freshwater pump types PVVF 1525-1532-2040 . . . . . . . . . . . . . page 29
Maintenance of separator vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 14

O26WE08IX.fm 43
Index
O
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41
Overhaul intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 13
Overhaul of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 33

P
Preparation of new gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 19
Prevention of scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 21

R
Removal of old gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18
Renewal of plate heat exchanger gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 18

S
Safety instructions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Safety precautions with the use of chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . page 23
Salinometer type DS-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
Scale inhibitor dosage equipment for feed water . . . . . . . . . . . . . . . . . . . . . . . . page 22
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 41
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Starting and stopping procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Stopping Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 9
Stopping the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 11
System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

T
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 37
Telefax . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Telephone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Test sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25
Testing the instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 38
Trouble shooting table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 25

W
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 5
Why you need to perform regular maintenance duties . . . . . . . . . . . . . . . . . . . . page 13
Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page 7

44 O26WE08IX.fm
 SOLD BY / 販売

Alfa Laval K.K. JAPAN / アルファ・ラバル 株式会社

TOKYO, JAPAN / 東京本社
〒108-0075
東京都港区港南2丁目12番23号
明産高浜ビル10Ｆ
TEL : 03-5462-2446
FAX : 03-5462-2455

OSAKA, JAPAN / 大阪支社

〒540-0028
大阪市中央区常磐町1丁目3番8号
中央大通 ＦＮ ビル13Ｆ
TEL : 06-6940-2253
FAX : 06-6940-2263

SHONAN CENTER / 湘南センター

〒253-0111
神奈川県高座郡寒川町一之宮7丁目11番2号
TEL : 0467-75-4403
FAX : 0467-75-3614